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MANUFACTURING

  • Injection Molding (Plastic/ Rubber/ Metal +)
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About Jaycon Systems
THE WORLD OF

JAYCON SYSTEMS

...where a bunch of geeks got together to make other people's ideas come to life.

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Our team will review your project and file and call or email in order to speak about any other requirements you may have in order to move forward. Payments can be made by ACH, bank deposit, or credit card.
Our most popular materials are ABS, PC, PP, PMMA, and Nylon. We also source other materials upon request in order to meet product requirements.
Ultimately, you're buying the units manufactured through the process of injection molding. The initial mold tooling cost our clients pay reflects the actual cost related to milling the block of material in order to make the negative shape of your part.
The instant quote includes the mold cost and the cost per unit manufactured. Shipping, box build assembly, special materials and/or requirements are not reflected in that price. Our team also offers DFM (design for manufacturability) services in order to help you reduce costs during production. This service is optional and is not included in the instant quote.
A mold is the tooling necessary to make plastic components.  The mold is a metal (steel or aluminum) block that is divided into two halves.  Each half has a cavity shaped as the negative of the part.  The two halves placed together and liquid plastic injected into them is what creates a plastic part.
Think of a cavity as an indentation in the mold that will allow the molten plastic to flow into to take shape of the desired product.
A family mold is a mold that consists of two or more parts of the same product, or parts of multiple products. An example would be a container and its lid being produced with the same mold.
This is not the same as a family mold. A multi-cavity mold is a mold consisting of cavities of the same product. For instance, a remote control requiring a front, a back, and a battery cover can all be made into a family mold. A multi-cavity mold could be used for plastic forks, for example, where one mold would have many cavities, producing more than one piece per shot.

We offer entry level, mid level, and mass production molds based on the customer's needs and product specs.

  1. Entry level molds made out of aluminum have an approximate 2,000 unit mold life or more depending on product complexity.
  2. Mid-level molds made out of P20 steel and typically have a life ranging from 10,000 to 50,000 pieces.
  3. Mass production molds are made out of hardened steel and usually have a life of 50,000+ pieces.
  4. For production runs between 2,000-10,000 pieces, our team considers project requirements to determine the most appropriate mold for our clients.
You can order as many units as the mold life allows. Keep in mind unit price is subject to slight change according to aspects such as current petrol prices, machine setup, shipping, and others.
Unfortunately, no. All molds stay in the factory and are recycled when they reach the final stage of their mold life.
We work with hand-picked manufacturers in and around Shenzhen, China who are able to mill our molds according to specs.
It takes about 15 business days to make an entry level mold and about 7 business days to receive an FAI (first article inspection).
In many instances, our clients send us files that are not optimized for manufacturability, or in other words, they aren't designed properly for injection molding machines. In those cases, we offer DFM (design for manufacturability) services for an extra charge, where our team can make slight modifications to your design to ensure it is ready for the process of being manufactured through injection molding.
We offer QC in form of FAI (first article inspection), where we ship 1-3 units — the first batch produced by the mold — directly to our clients so they can ensure that the manufactured piece is up to their standards. If the client approves the quality, we continue production, otherwise, we make modifications in the mold to ensure the highest quality on coming batches.
There are always chances of a part experiencing manufacturing defects due to improper 3D design. However, it is less likely to have defects if the mold has been designed to accuracy. To avoid defects or making changes to the mold after it has been made, it is important to keep in mind design requirements for injection molding. Read our guide on these requirements here.
We do not offer in-house testing, however, we work with third-party companies that offer a variety of testing.
We can certainly work with our clients in most box build assembly projects. Pricing is dependent on complexity and amount of your parts, along with any special requirements. We also offer Printed Circuit Board Assembly Sevices to go along with your plastics project.
Yes. Our sourcing team is able to help you source many different types of hardware needed for plastics. Our most sourced products are threaded inserts, screws, battery connectors and even foam cushions. Additional fees apply for all sourcing services.
There are no size restrictions when it comes to manufacturing a part by means of injection molding. However, keep in mind our quoting system is most optimized for smaller parts. If you believe the quote you have received for your large parts was inaccurate, give us a call and an engineer will analyze it and give you a more accurate quote.
Yes. We have a variety of reinforcements and fillers for our customers to choose from. The most popular ones are fiberglass, flame retardant, UV absorbers, and colorants.
Absolutely! You are welcome to give us a call at 888-226-4711. We usually set up consultations to speak about material selection, the overall process of manufacturing, timeline, and other requirements.